CN1426382A - 含低密度添加剂的纤维水泥建筑材料 - Google Patents
含低密度添加剂的纤维水泥建筑材料 Download PDFInfo
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Abstract
本发明涉及一种加到水泥纤维素纤维增强建筑材料中的低密度火山灰添加剂、中空陶瓷微球体或微球体与火山灰的组合或其它低密度添加剂的配方。此配方的优点是与目前的纤维水泥产品相比具有较轻的重量和较低的密度，同时不增加通常与纤维水泥混合物中轻质无机材料的加入相关的湿膨胀和冻－融降解。所述的低密度添加剂还赋予材料改善的热形稳定性。
Description
发明背景
发明领域
本发明涉及建筑材料及其制造方法，更具体地涉及将低密度添加剂(LDA)加至水泥纤维素纤维-增强建筑材料中。
背景技术
纤维-增强水泥(FRC)产品如耐水建筑钢板自1895年以来用于建筑。在最近的历史中，用于这种产品的增强纤维不仅包括石棉纤维，还包括纤维素纤维(参见澳大利亚专利515151)、金属纤维、玻璃纤维和其它中性与合成纤维。一般来说，这种建筑钢板的密度为大约为1.2-1.7g/cm3，密度变化一般通过制造中所用的纤维水泥浆的压浆和脱水以及纤维用量的改变而实现的。在这些密度中，基于水泥的基质具有很少的空隙，导致吸水性降低，而吸水性通常被认为是水泥基质良好耐用性能所必需的。
上述纤维水泥的密度意味着所述产品比相同尺寸的基于木材的产品更重并使加工性能降低。加工性能包括板的处理和装修的容易性。因此，纤维水泥建筑产品比木材和基于木材的产品更加难以切割、进行机械加工和受钉。在这方面，天然木板的密度范围一般是：对于干硬木为大约0.7-0.9g/cm3，对于干软木为大约0.38-0.6g/cm3。因此，期望具有类似于木材的密度的密度改性的纤维水泥材料以改善加工性能和使其能够更轻、更受钉，更易于切割和更易于成为欲制造机械加工产品。但是，如果要将密度改性的纤维水泥作相同范围的应用的话，这些性能必须在保持纤维水泥的耐用性、耐火性、防腐性和防水性的同时获得。
现有技术描述了如何可以将轻质无机粉末作为密度改性剂加到水泥或纤维-增强水泥材料中。FRC产品的低密度添加剂定义为具有大约0.8g/cm3(大约50lbs./cu.ft.)或更小的容积密度。所用的典型的低密度添加剂(LDA)包括低容积密度硅酸钙水合物(CSH)、膨胀性聚苯乙烯珠(EPS)、膨胀蛭石、膨胀珍珠岩、膨胀页岩和膨胀粘土。含有这些无机颗粒的基于水泥的材料的密度改性主要通过往材料中引入空隙而实现的。一般来说，在将材料浸入水中或与雨水长时间接触时这些孔隙被水填充。这导致这些材料具有较弱的湿至干外形稳定性(耐湿性)，较高的饱和质量和弱耐冻-融性。
因此，需要一种具有优于典型密度改性的产品的改善的湿或干外形稳定性的轻质FRC建筑材料和用于制造它的方法。其次，如果所述密度改性的材料用于相同的应用范围的话，轻质建筑材料应保持与不含密度改性剂的FRC产品类似的湿至干外形稳定性。此外，在某些应用中非常优选所述材料还具有低饱和质量、良好的耐冻-融性和高温外形稳定性。最后，还期望拥有这样的一种FRC建筑产品：其中，可以获得与木材和基于木材的产品更为接近的较低范围的密度和改善的耐用性。
发明概述
本发明评价了对两种FRC建筑材料性来说具有比典型的低密度添加剂更理想的低密度添加剂。这两种低密度添加剂为火山灰和中空陶瓷微球体。本发明的一个实施方案包括将火山灰(VA)加至FRC建筑材料中。第二个实施方案包括将中空陶瓷微球体(微球体)加至FRC建筑材料中。第三个实施方案包括将微球体与火山灰和/或其它典型的低密度添加剂的掺混物加到FRC建筑材料。将微球体与VA和/或其它低密度添加剂掺混的第三实施方案可能比仅加入火山灰的第一实施方案更为优选。依赖于考虑用于具体应用的性能，仅加入微球体的第二实施方案比上述的第一或第三实施方案更为优选。
与目前的FRC产品相比，含火山灰的第一实施方案的一个优点是它以经济的价格提供优于典型低密度添加剂的具有低密度和改善的加工性能以及改善的外形稳定性的产品。
第二实施方案包括在纤维-水泥产品中加入微球体。与目前的FRC产品相比，加入微球体的优点包括产品的低密度和改善的加工性能，且不具有与FRC混合物中加入轻质无机材料有关的增加的湿膨胀或冻-融降解。而且，微球体的加入提供改善的FRC材料的热形稳定性。
第三实施方案涉及在FRC材料中加入与VA和/或其它典型的低密度添加剂结合的微球体添加剂。将微球体与其低密度添加剂掺混是有利的，这是因为可以获得较低密度的FRC产品，并且由于VA和其它典型LDA比微球体密度低而导致重量百分比加入量较少(与仅加入微球体相比)。这还使纤维水泥获得较低的密度范围以进一步改善加工性能，同时微球体使低密度添加剂对湿-至-干外形稳定性和总耐用性的不利作用最小化。
因此，在本发明的一方面，提供一种建筑材料，所述建筑材料包含纤维-增强水泥配方和加到此配方中的低密度添加剂。与含有等量的不含低密度添加剂的纤维-增强水泥配方的建筑材料相比，配方中低密度添加剂的加入降低所述建筑材料的密度，同时与含有等量的不含低密度添加剂的纤维-增强水泥配方的建筑材料相比，含低密度添加剂的建筑材料增大的湿膨胀小于大约20％。更优选地，与含有等量的不含低密度添加剂的纤维-增强水泥配方的建筑材料相比，将低密度添加剂加到所述配方降低所述建筑材料的密度，同时与含有等量的不含低密度添加剂的纤维-增强水泥配方的建筑材料相比，所述低密度添加剂保持或减少建筑材料的湿膨胀。所述建筑材料的密度优选为大约1.2g/cm3或更小。
在本发明的另一方面，提供一种建筑材料配方以形成一种建筑产品。所述配方包含水凝粘合剂、集料、纤维和火山灰。在一个实施方案中，与由等量不含火山灰的配方制造的建筑产品相比，所述火山灰改善加工性能并将最终建筑产品的密度降低超过大约10％。在另一个实施方案中，含有火山灰的配方在最终产品的湿膨胀方面具有可被忽略的差别，从而与由等量不含火山灰的配方制备的建筑产品相比，所述产品保持或小于大约20％地增加湿膨胀。关于密度改性的实现程度，这种湿改变增加令人惊奇地低。正常使用相同配方成分时发现火山灰配方的湿膨胀差别是存在的。这种差别主要是由于原料表面积上的波动所致。
在本发明的另一方面，提供一种用于形成低密度建筑材料的方法。将水凝粘合剂、集料、火山灰和水混合造浆。将此浆加工成绿色成形物品。将此绿色成形物品固化形成低密度建筑材料。在一个实施方案中，通过热压处理法将物品固化。在另一实施方案中，形成的低密度建筑材料的密度为大约1.2g/cm3或更低，而湿膨胀为大约0.17％或更低。
在本发明的另一方面，一种建筑材料配方包含水凝粘合剂、集料、纤维和中空陶瓷微球体。最终建筑材料的密度为大约1.2g/cm3或更低。在一个实施方案中，在配方中提供大约4.1％-15％纤维素纤维。在另一实施方案中，与由等量不含微球体的配方制造的建筑材料相比，所述微球体将最终建筑产品的密度降低超过大约15％，甚至更优选超过大约30％。在另一实施方案中，与由等量不含微球体的配方制造的建筑材料相比，所述微球体降低最终产品的湿膨胀，优选降低超过大约5％，更优选超过大约10％。在一个优选的实施方案中，在配方中提供微球体与其它附加的低密度添加剂如火山灰和/或低容积密度CSH的组合。
在本发明的另一方面，提供了一种形成低密度建筑材料的方法，包括将水凝粘合剂、集料、纤维、中空陶瓷微球体和水混合造浆。将此浆加工成绿色成形物品。将此绿色成形物品固化形成低密度建筑材料。所得的建筑材料的密度为大约1.2g/cm3或更低。在一个实施方案中，将大于大约4％纤维混合造浆。在另一实施方案中，通过热压处理法将物品固化。
附图说明
图1为在冻-融试验以后含有和不含有中空陶瓷微球体的Hatschek制成板的MIP孔径分布图。
图2为在冻-融试验以后含有和不含有中空陶瓷微球体的Hatschek制成板的BET孔径分布图。
图3为在147次冻-融循环之后不表现出降解的含10wt.％中空陶瓷微球体的Hatschek制成板的SEM照片图。
图4为低密度添加剂加入、密度和强度之间的关系图。
具体实施方式
本发明的优选的实施方案描述一种将中空陶瓷微球体和/或火山灰两种低密度添加剂中至少一种混合的纤维-增强水泥建筑材料。可以认识到这些添加剂不仅可以用于本文所述的建筑材料类型(即纤维增强材料)，也可以用于其它建筑材料。此外，还考虑多种组合微球体和/或火山灰与其它密度改性剂结合以降低密度和改善建筑材料的总性能。而且，还考虑其它在获得低密度性能的同时保持或减少最终产品的湿膨胀，并改善加工性能、耐用性和其它性能(如下述)的类似于中空陶瓷微球体和火山灰的低密度添加剂在本发明的保护范围之内。
1.第一实施方案-火山灰
在第一实施方案中，本发明涉及将火山灰加到水泥纤维素纤维增强建筑材料中。火山灰为一般称为“空气珠光体”、“浮石”或“pumicsite”。通常火山灰是一种来自火山爆发期间的火山岩浆的自然玻璃。火山灰是一种由高温岩浆冷却而形成的较轻的砂沉积物，产生包含大约30wt.％结晶矿物和70wt.％无定形火山灰玻璃的材料。它的典型的容积密度为大约25-75lbs./cu.ft。通常这种火山灰随着的热的导入而膨胀改变形态，并得到典型容积密度范围为大约2-25lbs./cu.ft的较轻材料。膨胀火山灰可以具有从小于大约10微米至大约425微米的宽范围的粒径，且中值粒径的范围为大约20-100微米。所述化学组合物主要由硅石(SiO2)、氧化铝(Al2O3)和氧化钾(K2O)组成。
火山灰或膨胀火山灰可以从诸如以下的供应商得到：TuffliteInc.of Phoenix，Ariz.；California Industrial Minerals ofFriant，Calif.；US Pumice of Chatsworth，Calif.；Amcor Precastof Idaho Falls，Id.；Hess Pumice Products of Malad City，Id.；Kansas Minerals Inc. of Mankato，Kans.；Calvert Corporationof Norton，Kans.；Copar Pumice Company of Espanola，N.M.；C.R.Minerals of Santa Fe，N.M.；Utility Block of Alburquerque N.M.；和Cascade Pumice of Bend，Oreg。
本发明第一实施方案的一个优选的配方包含水凝粘合剂、集料、纤维、火山灰和添加剂。所述水凝粘合剂优选为波特兰水泥，但是还可以是但不限于高氧化铝水泥、石砂、研磨的颗粒状高炉矿渣水泥和石膏抹灰粉饰或它们的混合物。所述集料优选研磨的硅石砂，且可以是但不限于无定形硅石、硅藻土、稻壳灰、高炉矿渣、研磨炉渣、钢铁炉渣、矿质氧化物、矿质氢氧化物、粘土、菱镁石或白云石、聚合珠、金属氧化物和氢氧化物，或它们的混合物。所述纤维优选纤维素木桨，但是还可以是但不限于陶瓷纤维、玻璃纤维、矿绵、钢纤维和合成聚合纤维如聚酰胺、聚酯、聚丙烯、聚甲基戊烯、聚丙烯腈、聚丙烯酰胺、粘胶、尼龙、PVC、PVA、人造丝、玻璃陶瓷、碳或它们的混合物。所述添加剂可以包括但不限于含硅烟雾、地热硅石、阻燃剂、增稠剂、颜料、着色剂、增塑剂、分散剂、发泡剂、絮凝剂、防水剂、有机密度改性剂、铝粉、高岭土、氧化铝三水合物、云母、偏高岭土、碳酸钙、硅灰石、聚合树脂乳剂或它们的混合物。
火山灰可以用于多种含有不同比例的水凝粘合剂、集料、火山灰和添加剂的建筑产品以获得最佳的具体应用性能(如壁板、盖瓦、镶边、拱腹、瓦片下层背衬板等)。可以理解火山灰的百分含量可以依赖于目标应用而变化。一种优选的组合物可以包含大约5％-80％波特兰水泥、大约0％-80％硅石、大约4.1％-15％纤维素、大约0％-10％添加剂和大约2％-50％火山灰。典型的含火山灰的配方的一个具体实例如下：波特兰水泥(粘合剂) 28％硅石(集料) 54％纤维素(纤维) 7％金属氢氧化物(添加剂) 4％火山灰(LDA) 7％
优选水泥和硅石的细度指数为大约200to 450m2/kg。根据ASTMC204-96a测试水泥和硅石的细度指数。
可以在进行或不进行后加工的情况下，通过诸如以下的本领域技术人员已知的常规方法将所述材料从水溶体混合物或浆加工形成绿色成形物品：
● Hatschek板法；
● Mazza管法；
● Magnani法；
● 注压法；
● 挤出法；
● 手工敷层法；
● 模塑法；
● 铸造法；
● 压滤法；
● 机器内流动、成形轧制等等。
在澳大利亚专利515151中描述了用于获得最终产品的加工步骤和参数。
所述材料优选预固化至多80小时，最优选24小时或更小，以得到设定的配方。然后将所述材料在空气中固化(大约28天)，或者更优选在高温下进行热压处理，并在120-180℃下于蒸汽饱和的环境下压制3-30小时，最优选24小时或更小。固化的长度和时间取决于配方、制造工艺和物品的形式。
试验结果
密度和加工性能
纤维水泥材料中火山灰的加入以经济的价格降低了密度并改善了总体加工性能，同时降低了典型低密度添加剂的湿膨胀所观察到的湿膨胀。含火山灰的产品较轻，因此易于操作、钉和刻和紧压至目标形状。含火山灰的配方还减少当板靠近边缘(如3/8-3/4)受钉时的边缘破裂或碎散(如果有的话)。以下的表1和2例示了FRC配方和这些配方的试验结果，更为具体地证明加入火山灰以降低密度和改善加工性能的优点。
表1用于表2试验结果的配方
| 配方识别 | 波特兰水泥 | 硅石 | 纤维素 | 金属氢氧化物 | 膨胀火山灰 |
| 水凝粘合剂 | 集料 | 纤维 | 添加剂 | LDA | |
| B | 28.7 | 60.3 | 7.0 | 4.0 | |
| K | 28.7 | 52.8 | 7.0 | 4.0 | 7.5 |
表2含不和不含有火山灰的性能比较
| 试验方法 | 配方K175％火山灰 | 配方B对照号LDA |
| (O.D.)密度(g/cm3) | 1.11 | 1.34 |
| 钉穿透3(平衡条件)2材料中钉子的mm50mm(2英寸)＝钉子的长度标准偏差 | 45.41.1 | 33.01.0 |
1对于配方K，用7.5％火山灰代替对照物，配方B中的7.5wt.％集料。
2平衡条件-样品调节处在73±4°F的受控的大气压和50±5％湿度的条件下。指下文中用于钉穿透试验的定义和描述。
3指关于钉穿透试验的定义和下文的描述。
以上表2比较含有或不含有火山灰的10”×10”过滤器重压原型板的试验结果。原型板是通过以下方法制造的：用Hobart混合器混合目标配方以形成匀浆，然后在两层钢脱水板之间在3500psi下用Wabash压力机(模型#PC-75-4TM)压浆1分钟以形成一种单片板。在钢框架铸造模内用置于浆混合物下方和上方的钢丝网筛(30-40US目)支承浆。然后将单片板预固化最小大约12小时，并在高温和150℃蒸汽饱和环境中的压力下热压处理大约12小时。
在表2中，与等量的不含火山灰的配方，配方B，对照配方相比，含有7.5wt.％火山灰的配方K将密度大约降低约17％，从1.34g/cm3降至1.11g/cm3。等量配方在本文中定义为这样一种配方：其中，优选的LDA(如火山灰)被相同百分率的粘合剂、集料和/或添加剂代替，更优选被相同百分率的集料代替。这种降低的密度还改善受钉性，或者易于将钉入推入板中。试验表明钉穿透从33.0mm增至45.4mm，其中，50mm代表钉长，因而是能够实现的最大钉穿透。钉穿透试验由以下步骤组成：使用Paslode Impulse无线框架硬件枪(阳性代替)将分层堆积的板钉入以确保一致的钉入压力。所述的分层堆积的板一般包含堆积至大于钉子长度(20英寸或50mm)的高度的1/4-1/2”厚板。使用Senco 6d电镀夹紧的头钉(部分#GC21AABN)。
因此在一个实施方案中，与密度为大约1.3g/cm3的典型建筑钢板相比，上述的建筑材料配方导致最终产品的密度小于大约1.2g/cm3。更优选地，可以优选地调节建筑材料配方中火山灰的加入量以得到密度为大约1.2g/cm3或更小，或者与等量的不含火山灰的配方相比密度降低大约10％或更大的最终产品。还考虑加入更大量的火山灰进一步降低建筑产品的密度。
湿-干外形稳定性
与不含LDA的FRC配方相比，在重量百分比增加的基础上，含有常规密度改性剂的固化纤维水泥配方具有增加的湿膨胀和增加的湿吸收。所述第一实施方案相对于现有技术的优点是火山灰的加入获得理想的密度和加工性能，同时在以类似的重量百分比基础上加入时，其湿膨胀低于常规低密度添加剂。在建筑产品中，湿-干外形稳定性是装修产品的质量和耐用性所期望的，特别是在经受严重气候变化的外部应用中。良好的外形稳定性使在板或建筑防墙板或垫板之间任何可能的打开的缝隙最小化。良好的外形稳定性还减少了由于外形变化的防墙板或垫板与固定最终产品的支承骨架之间产生的应力导致的板破裂的可能性。
以下表3和4例示了FRC配方和这些配方的试验结果，更为具体地证明加入火山灰的优点在于降低密度，同时使在相同重量基础上加入其它低密度添加剂的特征性湿膨胀最小化。
3 用于表4试验结果的配方
| 配方识别 | 波特兰水泥 | 硅石 | 纤维素 | 金属氢氧化物 | 膨胀火山灰 | 膨胀珍珠岩 |
| 水凝粘合剂 | 集料 | 纤维 | 添加剂 | LDA | LDA | |
| B | 28.7 | 60.3 | 7.0 | 4.0 | ||
| K | 28.7 | 52.8 | 7.0 | 4.0 | 7.5 | |
| L | 28.7 | 55.3 | 7.0 | 4.0 | 5.0 |
表4火山灰和珍珠岩的湿膨胀比较
| 配方 | 描述 | O.D.密度(g/cm3) | 湿膨胀％ | ％相对于对照物湿膨胀增加 |
| B2 | 对照-无LDA | 1.33 | 0.18±0.02 | |
| K3 | 7.5％VA | 1.11 | 0.17±0.02 | -5.5 |
| L | 5％珍珠岩 | 1.22 | 0.22±0.02 | 22.2 |
1湿膨胀为从饱和到烘干条件下的产品长度的变化。％变化湿膨胀方程为：
2在关于优选的实施方案的整个描述中，配方B用作对照。但是，由于没有一个包含配方B的样品用于所有的试验，在这些试验结果中可以发现任何样品的正常差别。
3对于配方K已用7.5％火山灰代替7.5wt.％来自对照物，配方B的集料。
以上的表4显示了10”×10”过滤器重压的原型板的结果，比较了含有7.5wt.％火山灰和含有典型低密度添加剂的5.0％珍珠岩(购自Harborlite公司的Harborlite 2000)的配方。含有5.0％珍珠岩的配方L相对于对照组湿膨胀增加22.2％，而含有7.5％火山灰的配方K实际上表现出相对于对照组湿膨胀降低大于大约5％。
因此，火山灰的加入提供了比以等量或较低重量百分比加入的典型密度改性剂更好的外形稳定性。这使火山灰在以相对于常规低密度添加剂而言以等量或更高量加入时，取得更低的密度和更好的加工性能。
更具体地，可以调节火山灰的加入以使其与等量的不含火山灰的配方相比表现出可以忽略的湿膨胀差异。在一个实施方案中，优选与由等量不含火山灰的配方制造的建筑产品相比，火山灰将最终产品的湿膨胀增加小于大约20％，更优选降低最终产品的湿膨胀。在一个优选的实施方案中，由含有火山灰的配方制造的建筑产品的湿膨胀为大约0.17％或更小。
2.
第二实施方案-中空陶瓷微球体
本发明的第二实施方案包括将中空陶瓷微球体加至水泥纤维素纤维-增强建筑材料。可以在包含火山灰的第一实施方案上优选含中空陶瓷微球体的第二实施方案，因为FRC材料中微球体的加入具有更好的耐湿性和其它耐用性优点，包括耐冻-融性和热形稳定性。可以认识到第二实施方案的优选实施方案不限于这些类型的微球体或建筑材料。因此，还考虑其它类型的填充剂和建筑材料。
微球体可以是天然、合成或副产品。所述的材料可以是晶体，但更典型地为非晶体或玻璃。一个优选类型的微球体为已知作为空心微珠的中空陶瓷微球体。空心微珠是一种煤灰副产品，它一般是通过浮选法从飞尘中分离的，其中球体漂浮至澄清器、池塘或湖的水表面。例如，所述的微球体可以根据名称Extendospheres、Recyclospheres和Zeeospheres购得，并可以从诸如以下的供应商购得：PQ Corporation of Chattanooga，Tenn.；ZeelanIndustries Inc./3M of St.Paul，Minn.；Sphere Service，Inc.of Oak Ridge，Tenn.；和Advanced cement Technologies(A.C.T.)of Blaine，Washington。
所述微球体的典型粒径为大约12-300微米，中值粒径范围为大约80-120微米。当然这些尺寸可以在样品之间变化。优选的微球体一般包含大约62％-65％硅石(SiO2)、大约23％-26％氧化铝(Al2O3)和大约3.0％to 4.0％氧化铁(Fe2O3)。当往建筑材料中加入微球体时，所述微球体在所述材料中引入孔，使材料不会容易地被水填充，从而对材料是有利的，因为它具有了较低的饱和质量、改善的湿-干外形稳定性和改善的耐冻-融性。
第二实施方案的另一优选的配方包含水凝粘合剂、集料、纤维、中空陶瓷微球体和添加剂。可以认识到，多种用于第二实施方案的优选的配方的组分包括任何上述关于在第一实施方案中的每一种组分所列的材料。所述材料还可以由在第一实施方案中所列的多种常规方法和固化条件制造。如果可以应用的话，原料、方法、步骤或条件的优选与第一实施方案类似。
所述微球体可以用于多种完全具有不同比例的水凝粘合剂、集料、微球体和添加剂的建筑产品以获得具体应用(如壁板、盖瓦、镶边、拱腹、下层背衬板等)的最佳性能。一种优选的组合物可以包含大约5％-80％波特兰水泥、大约0％-80％硅石、大约4.1％-15％纤维素、大约0％-10％添加剂和大约2％-90％微球体。含有微球体的典型配方的一个具体的实例如下：波特兰水泥(粘合剂) 28.7％硅石(集料) 50.3％纤维素(纤维) 7％金属氢氧化物(添加剂) 4％微球体(LDA) 10％。
可以认识到微球体的百分比可以依赖目标应用而变。例如，高加入百分比率(至多大约90wt.％)微球体对于建筑材料和需要某类型的耐火级别的系统是合适的。微球体的大量加入给材料提供了低热收缩性。
试验结果
密度
用微球体降低密度在不牺牲纤维水泥产品供应物的耐用性(如外形稳定性)和结构完整性的情况下，改善了较厚产品的总加工性能。这些属性对于厚度大于大约八分之三英寸(＞3/8”)产品而言特别有用。其次，含有微球体的产品更轻，因而易于操作含有微球体的产品更易于钉和刻/紧压至目标形状。而且，微球体配方减少当板靠近边缘(如3/8-5/8)受钉时的边缘破裂或碎散(如果有的话)。
以下表5和6显示了配方及用于FRC配方的试验结果，更为具体地例示了将微球体加至配方以改善密度和加工性能的优点。
表5 用于表6试验结果的配方
| 配方识别 | 波特兰水泥 | 硅石 | 纤维素 | 金属氢氧化物 | 微球体 |
| 水凝粘合剂 | 集料 | 纤维 | 添加剂 | LDA | |
| B | 28.7 | 60.3 | 7.0 | 4.0 | |
| A | 28.7 | 50.3 | 7.0 | 4.0 | 10.0 |
表6 含与不含微球体的性能比较
| 试验方法 | 配方A110％微球体 | 配方B对照物无LDA |
| 密度(平衡条件)2(g/cm3) | 1.16 | 1.39 |
| 钉穿透(平衡条件)材料中钉的mm50mm(2英寸)＝钉长标准偏差 | 47.00.9 | 31.71.4 |
1配方A中10％微球体代替对照物，配方B中10％集料。
2平衡条件-样品调节至73±4°F受控的大气压和50±5％湿度条件下。
表6显示了关于配方A和B的3’×5’Hatschek制造板试验结果。当与等量的不含微球体的配方(配方B)相比时，含有10wt.％微球体的配方将密度降低大约15％，从1.39g/cm3到1.16g/cm3。此外，改善了将钉子推入板内的容易性。试验表明钉穿透从31.7mm增至47.0mm，其中，50mm代表钉长和可能实现的最大钉穿透。
总之，这些原型试验和由试验生产的产品已表现出每加入10％微球体密度降低大约15％，和显著的受钉性改善。因此，与等量不含微球体的配方相比，加入微球体可以有利地将FRC建筑材料的密度降低大于大约15％，甚至更优选大于大约30％。本发明者考虑随着微球体的加入，材料的密度可以降低至大约0.9g/cm3(参见下表10)，更优选甚至低至大约0.5g/cm3。
湿-干外形稳定性
如上述，在百分比重量增加的基础上，含常规密度改性剂的固化纤维水泥配方具有增加的湿膨胀和增加的吸收。优选实施方案相对于现有技术的一个优点是用于降低密度的微球体的并未加入增加从湿至干的湿膨胀。由于前面第一实施方案中所述的多种原因这是有用的。
以下表7显示了含和不含微球体的3’×5’Hatschek制造板的试验结果。含10％微球体的配方A与不含微球体的配方B相比，保持或更优选地降低了湿膨胀。配方A和B在上表5中。
表7含和不含微球体的湿膨胀比较
| 试验方法 | 配方A110％微球体 | 配方B对照物无LDA |
| 密度(平衡条件)2(g/cm3) | 1.16 | 1.39 |
| 湿膨胀％变化 | 0.1 5±0.02 | 0.16±0.02 |
1配方A中10％微球体代替对照物，配方B中10％集料。
2平衡条件-样品调节至73±4°F受控的大气压和50±5％湿度条件下。
表8-10显示了配方和用于10”×10”过滤器重压的原型板的试验结果，比较了微球体和增加湿膨胀的常规密度改性剂。常规密度改性剂包括低容积密度硅酸钙水合物(CSH)和膨胀聚苯乙烯、蛭石、珍珠岩、页岩和粘土。
表8 用表9和10试验结果的配方
| 配方识别 | 波特兰水泥 | 硅石 | 纤维素 | 金属氢氧化物 | 微球体 | 低容积密度CSH | 膨胀珍珠岩 |
| 水凝粘合剂 | 集料 | 纤维 | 添加剂 | LDA | LDA | LDA | |
| B | 28.7 | 60.3 | 7.0 | 4.0 | |||
| C | 35.2 | 52.8 | 8.0 | 4.0 | |||
| D | 26.8 | 40.2 | 8.0 | 25.0 | |||
| E | 26.8 | 40.2 | 8.0 | 25.0 | |||
| F | 28.7 | 55.3 | 7.0 | 4.0 | 5.0 |
以下表9数据显示了5％装载量的常规低密度添加剂、低容积密度CSH(来自Celite公司的Silasorb)，相对于照物，配方B增加了湿膨胀。
表9低容积密度CSH的湿膨胀
| 配方识别 | 描述 | 平衡密度1(g/cm3) | 湿膨胀％ |
| B | 对照 | 1.41 | 0.1 62±0.02 |
| F2 | 5.0％低容积密度CSH | 1.27 | 0.1 88±0.02 |
1平衡条件-样品调节在73±4°F受控的大气压和50±5％湿度的条件下
2配方F中的5％低容积密度CSH代替对照物，配方B中5％的集料
以下表10比较了两种配方和相同的碱配方，一种含25wt.％微球体，另一种含25wt.％珍珠岩(购自Aztec珍珠岩的Aztec XX)。两种珍珠岩和微球体配方将对照配方C的密度从1.3g/cm3降至大约0.9g/cm3，珍珠岩配方的湿膨胀增加，而微球体配方的湿膨胀降低。
表10-微球体和珍珠岩的湿膨胀比较。
| 配方 | 描述 | 平衡密度(g/cm3) | 湿膨胀％ |
| C | 对照 | 1.31 | 0.230±0.02 |
| D | 25％微球体 | 0.90 | 0.202±0.02 |
| E | 25％珍珠岩 | 0.89 | 0.275±0.02 |
1平衡条件-样品调节在73±4°F受控的大气压和50±5％湿度的条件下
2对于配方D和E，微球体代替对照物，配方C中的集料和水凝粘合剂。
因此，纤维水泥配方中微球体的加入具有保持或降低最终产品湿膨胀的效果。优选地，可以调节微球体的加入，以与相似的不含微球体的配方相比，将湿膨胀降低大约5％，更优选降低大约10％或更多。
耐冻-融性
耐冻-融性指材料在经受重复的冷冻和融化循环时对破坏的耐受性。例如，混凝土可能被霜冻，特别是被重复的冷冻和融化循环破坏。破坏一般开始于表面的破裂并逐渐延伸至内部，虽然深度破裂可能发生。与冷冻有关的破坏一般不发生，除非孔中存在足量的水，且这种破坏在低水-与-水泥比率和低渗透性混凝土中最小。
与高密度混凝土类似，冻-融破坏在高密度纤维水泥中最小。在优选的实施方案中，FRC配方中微球体的加入产生较低密度的固化产品，这种产品保持耐冻-融性，与现有技术不同的地方是配方中密度改性剂的加入降低了材料的耐冻-融性。
图1和2显示了使用MIP(水银侵入孔隙度测定)和BET(Brunauer，Emmett和Teller)方法的3’×5’Hatschek制造板的孔径分布图。含有10wt.％微球体的配方在147次冻-融循环之后的孔径分布变化比不含微球体的配方B在126次循环之后的变化小。这证明了微球体配方对普通冻-融破坏的结构变化的耐受性。为了进一步支持微球体配方对冻-融破坏的耐受性，图3显示了含有10wt.％微球体的Hatschek制造板(3’×5’)的SEM(扫描电子显微镜)图，表明在147次冻-融循环之后无降解的迹象，而其它木质水泥复合物一般在此阶段具有降解。
图3的冻-融试验是根据以下方法完成的：ASTM(美国标准试验方法)C666A，标题为“Standard Test Method for Resistance ofConcrete to Rapid Freezing and Thawing.(混凝土对快速冷却和融化的耐受性的标准试验方法)”。该试验方法具有两种不同的过程，A和B。依照过程A，即将样品浸在水中进行同时快速冷冻和融化，对在空气中快速冷冻和在水中快速融化(过程B)。定期地从冻-融循环中除去样品，并视觉检查降解如整个样品和总结构完整性的破裂、湿膨胀、海绵状/潮湿。当降解程度为样品不能保持在一起并因而不能用作建筑产品时，从冻-融循环中除去样品。
高温外形稳定性
降低建筑材料的热收缩防止建筑部件中存在的高温应力张力。这种改善的热外形稳定性使建筑部件在装配用火下保持为火的防护物且不会破裂、分离和使火快速扩散。
以下表11和12显示了FRC配方和10”×10”过滤器重压的原型板的试验结果，更为具体地例示在配方中加入微球体以改善高温外形稳定性的优点。
表11-用于表12试验结果的配方
| 配方识别 | 波特兰水泥 | 硅石 | 纤维素 | 金属氢氧化物 | 微球体 | 低容积密度 |
| 水凝粘合剂 | 集料 | 纤维 | 添加剂 | LDA | LDA | |
| A | 28.7 | 50.3 | 7.0 | 4.0 | 10.0 | |
| B | 28.7 | 60.3 | 7.0 | 4.0 | ||
| F | 28.7 | 55.3 | 7.0 | 4.0 | 5.0 | |
| G | 28.7 | 50.3 | 7.0 | 4.0 | 10.0 | |
| H | 28.7 | 40.3 | 7.0 | 4.0 | 20.0 |
表12微球体和低容积密度CSH热收缩性比较
| 配方 | 描述 | 平衡密度2(g/cm3) | 热收缩1(％) |
| B | 对照 | 1.41 | 3.07 |
| F3 | 5.0％低容积密度CSH | 1.21 | 7.27 |
| G3 | 10.0％低容积密度CSH | 1.15 | 8.09 |
| A3 | 10.0％微球体 | 1.15 | 4.41 |
| H3 | 20.0％微球体 | 1.01 | 4.21 |
1指以下关于热收缩试验的描述的正文。
2平衡条件-样品调节在73±4°F受控的大气压和50±5％湿度的条件下
3配方F、G、A和H中所述百分比的LDA代替对照物，配方B中相同百分比的的集料。
在较低的装载水平(如大约10-20％)下，微球体使在纤维水泥配方中加入典型有机密度改性剂时一般会发生的高温热收缩最小化。表12表示所得的关于含有10wt.％微球体的配方A对含有10wt.％低容积密度CSH(来自Celite公司的Silasorb)的配方G的热收缩百分率的结果。与对照物(配方B)相比，两种配方均将密度降低大约1.4-1.15g/cm3，但含有低容积密度CSH的配方具有几乎两倍于含微球体的配方的热收缩。而且，含有20.0wt.％微球体和密度为大约1.0g/cm3的配方H的热收缩比仅含5.0％低容积密度CSH(来自Celite公司的Silasorb)和密度为大约1.2g/cm3的配方F小40％以上。
使用热机械分析仪(TMA)测定高温热收缩。将样品分割成10份厚度至多为12mm的25mm。饱和样品的温度以20℃/分的速率上升至950℃，用宏膨胀探头测定样品外形。热收缩看作从25℃至950℃的总外形变化，并报道为总最初长度的百分率。
在纤维-水泥配方中使用微球体的另一个优点是热收缩随微球体加入的增多而降低。微球体的热收缩与加入的重量百分比成反比，而常规密度改性的热收缩与加入的重量百分比成正比。因此，较高加入量的微球体(至多大约90wt.％)的配方比较低加入量(至多大约20wt.％)的配方具有较低的热收缩。
以下表13提供了具有高加入量的微球体的配方，而表14提供了高温热收缩结果。具有70和90wt.％微球体加入量的配方I和J产生的热收缩结果分别为大约2.7％和1.1％。配方I和J的热收缩通过以下方法测得：切割大约10×10×40mm长的样品，烘炉干燥，用马弗炉在1000℃的温度下烘烤1小时，并冷却至烘炉干燥条件。通过测量烘炉干燥至1000℃的总长度差别，并除以最初烘炉干燥长度来确定热收缩百分比。
表13用于表14结果的配方
| 配方识别 | 波特兰水泥 | 含硅烟雾 | 纤维素 | 微球体 |
| 水凝粘合剂 | 集料 | 纤维 | LDA | |
| I | 26.2 | 2.9 | 0.9 | 70.0 |
| J | 8.7 | 1.0 | 0.3 | 90.0 |
表14 高加入量的微球体配方的热收缩
| 配方识别 | 热收缩％ |
| I | 2.7 |
| J | 1.1 |
因此，在20％微球体用于纤维水泥配方的实施方案中，与等量的由不含微球体的配方制造的产品相比，最终产品的热收缩增加低于大约50％。如上述，随着微球体百分率的增加，热收缩百分比降低，甚至降低至以下的某一点：其中，与不含微球体的产品相比，含有微球体的最终产品表现出降低的热收缩，优选降低大约10％-大约70％。更为具体地，含有微球体的产品的热收缩优选小于大约4％。
第三实施方案-微球体和其它添加剂
本发明的第三实施方案涉及在水泥纤维素纤维-增强建筑材料中加入与火山灰和/或其它低密度添加剂组合的中空陶瓷微球体。关于火山灰和中空陶瓷微球体的描述分别见第一和第二实施方案的详细描述。如果FRC产品可以获得较低范围的密度和改善的耐湿性和耐用性能的话，则含有微球体和低密度添加剂的掺混物的第三实施方案比含有VA的第一实施方案更优选。但是，单独加入微球体的第二实施方案比第三实施方案优选，因为单独加入微球体提供了最好的耐用性能。第二实施方案至第三实施方案的优选依赖于在具体应用中耐用性的相对重要性。
类似于第一和第二实施方案，第三实施方案的一个优选的配方包含水凝粘合剂、集料、纤维、中空陶瓷微球体、低密度添加剂和其它添加剂。可以认识到第三实施方案中的多种组分可以包括任何上述关于第一实施方案中的各种组分所列的材料。第三实施方案还可以由在第一实施方案中所列和所述的常规方法和固化条件制造。如果可以应用的话，原料、方法、步骤或条件的优选与第一实施方案类似。
微球体与VA和/或低密度添加剂的掺混可以用于多种具有不同比例的水凝粘合剂、集料、低密度添加剂和其他添加剂的建筑产品以获得最佳的具体应用性能(如壁板、盖瓦、镶边、拱腹、瓦片下层背衬板等)。第三实施方案中的一个优选的组合物可以包含大约5％-80％波特兰水泥、大约0％-80％硅石、大约4.1％-15％纤维素、大约0％-10％添加剂和大约2％-60％微球体和其它典型LDA。含有微球体和典型低密度添加剂的典型配方的一个具体实例如下：波特兰水泥(粘合剂) 28.7％硅石(集料) 50.3％纤维素(纤维) 7％金属氢氧化物(添加剂) 4％微球体(LDA) 10％火山灰(LDA) 5％
可以认识到微球体和其它LDA’s包括VA的百分率可以依赖于目标应用而变。
试验结果
兼耐用性的较低密度
微球体与VA或其它典型低密度改性剂如低容积密度CSH或膨胀聚苯乙烯珠、粘土、蛭石、珍珠岩和页岩的掺混具有许多优点。一个优点是如果VA和其它典型LDA的密度低于微球体，则可以较低的总重量百分比加入量(与仅含微球体的情况相比)获得相当或较低的密度。掺混物的较低加入比率是更为经济的，且微球体使与典型的有机密度改性剂的加入有关的湿膨胀最小化。微球体与其它典型低密度添加剂掺混的另一个优点是FRC产品可以获得较低的密度范围，并保持充足的产品的操作强度。因此，可以加入较高装载水平(以重量百分比为基础)的微球体与其它LDA的组合物，同时使典型的低密度添加剂对外形稳定性和总耐用性的不利作用最小化。
但是，在本文所述的所有实施方案中加入低密度添加剂不是降低基于水泥的配方的密度的唯一方法。由水泥和集料组成但不含纤维或或低密度添加剂的配方的密度范围为大约1.8-2.1g/cm3。水泥配方中加入纤维是有利的，因为纤维除了提供强度和适于受钉的产品以外还降低密度。含有大于大约4wt.％纤维的纤维水泥配方的密度范围一般大约为1.2to 1.4g/cm3。已发现，含有大约4wt.％或更低的纤维的FRC配方的不具有充足的强度和装修延展性。这些FRC产品一般太脆，并在装修过程中受钉时产生破裂和爆裂。可选择地，大于大约15wt.％的纤维加入量可能在某些应用是不期望的，因为FRC配方中的纤维导致湿膨胀、渗透性增加，并总体上牺牲耐用性。
因此，必须有利地测定FRC产品的正确的纤维平衡，它取决于具体产品的厚度和形状。在一个实施方案中，优选大约4.1％-15％的纤维百分率。将低密度添加剂加至FRC配方以提供相对于纤维加入的附加的密度降低。但是一般来说，LDA加入越多，FRC产品的强度性能越低。因此，LDA加入是有限的，因为FRC产品应该优选保持用于充足操作和装修的最小强度。最大LDA加入取决于多种因素如LDA、具体LDA的装载水平和具体FRC产品的形状。所需的最小强度还取决于FRC产品的形状和厚度。图4显示了微球体wt.％加入量与10”×10”过滤器重压的原型板的密度和强度的一般联系。
以下表15-17例示了FRC配方和10”×10”过滤器重压的原型板的试验结果，更为具体地例示了将微球体与其它低密度添加剂一起掺混以获得低密度范围和改善耐用性的优点。
表15用于表16和17的配方
| 配方识别 | 波特兰水泥 | 硅石 | 纤维素 | 金属氢氧化物 | 微球体 | 低容积密度 |
| 水凝粘合剂 | 集料 | 纤维 | 添加剂 | LDA | LDA | |
| B | 28.7 | 60.3 | 7.0 | 4.0 | ||
| G | 28.7 | 50.3 | 7.0 | 4.0 | 10.0 | |
| M | 28.0 | 49.0 | 7.0 | 4.0 | 12.0 | |
| N | 28.4 | 49.6 | 7.0 | 4.0 | 6.0 | 5.0 |
| O | 28.7 | 51.3 | 7.0 | 4.0 | 6.0 | 3.0 |
表16比较了含有12wt.％微球体的配方M、含有9wt.％微球体与低容积密度CSH的掺混物的配方O和不含低密度添加剂的对照物的密度。配方O中所用的低容积密度CSH由James Hardie使用采用硅石、石灰和水的方法生产，所述方法产生基本上为雪硅钙石形式CSH的低容积密度材料。进一步的细节描述在1998年4月9日提交的美国专利申请序列号09/058,444中，这里引用其全文作为参考。与对照物相比，配方M和O的密度的降低没有明显的差别，但低密度添加剂和掺混物(配方O)的总加入量比仅含微球体的配方M小3％。对于配方M和O，水凝粘合剂和集料的wt.％的细微差别对密度性能没有影响。
表16-密度比较
| 配方识别 | 描述 | O.D.密度(g/cm3) |
| B | 对照-无LDA | 1.31 |
| M1 | 12％微球体 | 1.09 |
| O1 | 6％微球体3％低容积密度CSH | 1.11 |
1配方M和O中LDA所述百分比的LDA代替不含LDA的对照物，配方B中相等百分比的集料
以下表17显示了四种主要仅在多种低密度添加剂的加入量方面存在变化的10”×10”过滤器重压原型板和不含任何低密度添加剂的对照物的试验结果。结果表明含有12wt.％微球体的配方M相对于对照物将密度从1.35g/cm3降至1.16g/cm3，但具有11wt.％加入量的微球体/低容积密度CSH(来自Celite的Silasorb)掺混物的配方N将密度进一步降至1.10g/cm3。而且，含有11wt.％微球体/低容积密度CSH掺混物的配方N和不含低密度添加剂的对照物的湿膨胀无明显差别，分别为0.167和0.163％。相比之下，仅含10wt.％低容积密度CSH的配方G提供大约与11wt.％掺混物的配方N相同的密度，但具有明显较高的0.197％的湿膨胀。配方中水凝粘合剂和集料的细微wt.％差别对密度或湿膨胀性能没有影响。
表17-湿膨胀比较
| 配方识别 | 描述 | O.D.密度(g/cm3) | 湿膨胀％ |
| B | 对照-无LDA | 1.35 | 0.163±0.02 |
| M | 12％微球体 | 1.16 | 0.156±0.02 |
| N | 6％微球体5％低容积密度CSH | 1.10 | 0.167±0.02 |
| G | 10％低容积密度CSH | 1.12 | 0.197±0.02 |
1配方M、N和G中所述百分比的LDA代替不含LDA的对照物，配方B中相等百分比的集料。
结论
一般来说，可以认识到本发明的优选的实施方案，更具体地，含有添加剂火山灰、中空陶瓷微球体或微球体、火山灰和/或添加剂的组合的纤维-增强建筑材料具有许多优于现有技术的优点。这些材料具有低于常规纤维水泥建筑产品的低密度。这样能够生产较轻从而易于操作、切割、受钉和装修的较厚产品(如3/8”-1.0”)。
所述材料还具有改善的湿-干外形稳定性，并改善所述建筑材料的耐用性，从而使建筑物护墙板不会过度地收缩和破裂。而且，护墙板或垫板之间的过量空隙在湿度变化之后或从湿转入干季节时不会打开。
关于至少包含中空陶瓷微球体的配方和建筑产品，与大部分的无机密度改性剂纤维水泥材料不同的是，所述材料的耐冻-融性在较低密度下保持的。这赋予这些材料在经历频繁的冷冻和融化条件下的良好耐用性。
这些包含微球体的材料由于其具有相对于低密度添加剂的改善的热形稳定性，因而还具有改善的耐火性能。因此，这些材料在装配用火中稳定地用作一种建筑构件，从而使所述材料可以保持为火的防护物，且不会破裂、分离和使火快速扩散。
所述的优选的实施方案用于多种建筑产品应用，包括但不限于建筑物防墙板(内部和外部)、瓦片背衬板(墙和地板)、壁板、拱腹、镶边、盖瓦、栅栏和铺面。提供以上所例举和描述的实施方案仅仅作为本发明某些优选实施方案的例子。本领域技术人员可以在不背离本发明的精神和范围的情况下对本文所述的实施方案作多种改变或修改。
Claims (68)
1.一种建筑材料，所述建筑材料包含：
一种纤维-增强水泥配方；和
一种加到此配方的低密度添加剂，其中，与含有等量的不含低密度添加剂的纤维-增强水泥配方的建筑材料相比，所述的低密度添加剂降低了建筑材料的密度，同时与含有等量的不含低密度添加剂的纤维-增强水泥配方的建筑材料相比，含低密度添加剂的建筑材料增加的湿膨胀小于大约20％；
其中，所述建筑材料的密度为大约1.2g/cm3或更小。
2.根据权利要求1所述的建筑材料，其中，所述的建筑材料的密度为大约0.5-1.2g/cm3。
3.根据权利要求1所述的建筑材料，其中，所述建筑材料的密度为大约0.9-1.1g/cm3。
4.根据权利要求1所述的建筑材料，其中，与含有等量的不含低密度添加剂的纤维-增强水泥配方的建筑材料相比，所述低密度添加剂保持或降低建筑材料的湿膨胀。
5.根据权利要求1所述的建筑材料，其中，所述低密度添加剂的中值粒径为大约20-120μm之间。
6.根据权利要求1所述的建筑材料，其中，所述低密度添加剂为火山灰。
7.根据权利要求6所述的建筑材料，其中，所述配方包含大约2-50％火山灰。
8.根据权利要求1所述的建筑材料，其中，所述低密度添加剂包含中空陶瓷微球体。
9.根据权利要求8所述的建筑材料，其中，所述配方包含大约2％-90％中空陶瓷微球体。
10.根据权利要求8所述的建筑材料，其中，除中空陶瓷微球体以外，所述配方还包含第二种低密度添加剂。
11.根据权利要求10所述的建筑材料，其中，所述第二种低密度添加剂为火山灰。
12.根据权利要求10所述的建筑材料，其中，所述第二种低密度添加剂为硅酸钙水合物。
13.根据权利要求12所述的建筑材料，其中，所述配方包含至多大约30％低容积密度硅酸钙水合物。
14.根据权利要求1所述的建筑材料，其中，所述配方包含大于大约4％的纤维。
15.根据权利要求14所述的建筑材料，其中，所述配方包含纤维素纤维。
16.一种用于形成建筑产品的建筑材料配方，所述配方包含：
一种水凝粘合剂；
一种集料；
纤维；和
火山灰。
17.根据权利要求16所述的配方，其中，所述水凝粘合剂为波特兰水泥。
18.根据权利要求17所述的配方，所述配方包含大约5％-80％波特兰水泥。
19.根据权利要求16所述的配方，其中，所述集料包含硅石。
20.根据权利要求19所述的配方，所述配方包含大约0％-80％硅石。
21.根据权利要求16所述的配方，其中，所述纤维为纤维素木桨。
22.根据权利要求21所述的配方，所述配方包含大约4.1％-15％纤维素纤维。
23.根据权利要求16所述的配方，所述配方还包含大约0％-10％添加剂。
24.根据权利要求16所述的配方，所述配方包含大约2％-50％火山灰。
25.根据权利要求16所述的配方，其中，所述火山灰为膨胀火山灰。
26.根据权利要求25所述的配方，其中，所述膨胀火山灰的容积密度为大约2-25lbs/cu.ft。
27.根据权利要求25所述的配方，其中，所述膨胀火山灰的中值粒径范围为大约20-100微米。
28.根据权利要求16所述的配方，其中，与由等量的不含火山灰的配方制造的建筑产品相比，所述火山灰将最终建筑产品的密度降低大于大约10％。
29.根据权利要求16所述的配方，其中，与由等量的不含火山灰的配方制造的建筑产品相比，所述火山灰将最终建筑产品的湿膨胀增加了小于大约20％。
30.一种低密度建筑材料的形成方法，所述方法包括：
将水凝粘合剂、集料，火山灰和水混合造浆；
将此浆加工成绿色成形物品；和
将此绿色成形物品固化形成低密度建筑材料。
31.根据权利要求30的方法，所述方法还包括将纤维与水凝粘合剂、集料、火山灰和水混合造浆。
32.根据权利要求30的方法，其中，所述纤维为纤维素。
33.根据权利要求30的方法，其中，将大于大约4％的纤维素纤维与水凝粘合剂、集料、火山灰和水混合。
34.根据权利要求30的方法，所述方法还包括将添加剂与水凝粘合剂、集料、火山灰和水混合造浆。
35.根据权利要求30的方法，其中，所述低密度建筑材料的密度为大约1.2g/cm3或更小。
36.根据权利要求30的方法，其中，所述低密度建筑材料的湿膨胀为大约0.17％或更小。
37.根据权利要求30的方法，其中，通过热压处理将所述物品固化。
38.一种用于形成建筑产品的建筑材料配方，所述建筑材料配方包含：
一种水凝粘合剂；
一种集料；
纤维；和
中空陶瓷微球体；
其中，所述最终建筑材料的密度为大约1.2g/cm3或更小。
39.根据权利要求38所述的配方，其中，所述水凝粘合剂为波特兰水泥。
40.根据权利要求39所述的配方，所述配方包含大约5-80％波特兰水泥。
41.根据权利要求38所述的配方，其中，所述集料包含硅石。
42.根据权利要求41所述的配方，所述配方包含大约0％-80％硅石。
43.根据权利要求38所述的配方，所述配方还包含大约0％-10％添加剂。
44.根据权利要求38所述的配方，其中，所述纤维为纤维素木桨。
45.根据权利要求44所述的配方，所述配方包含大约4.1％-15％纤维素。
46.根据权利要求38所述的配方，其中，所述微球体为空心微珠。
47.根据权利要求38所述的配方，所述配方包含大约5％-30％微球体。
48.根据权利要求38所述的配方，所述配方包含至多大约90％微球体。
49.根据权利要求38所述的配方，其中，与由等量的不含微球体的配方制造的建筑产品相比，所述微球体将最终建筑产品的密度降低大于大约15％。
50.根据权利要求38所述的配方，其中，与由等量的不含微球体的配方制造的建筑产品相比，所述微球体将最终建筑产品的密度降低大于大约30％。
51.根据权利要求38所述的配方，其中，与由等量的不含微球体的配方制造的建筑产品相比，所述微球体基本上保持最终产品的湿膨胀。
52.根据权利要求38所述的配方，其中，与由等量的不含微球体的配方制造的建筑产品相比，所述微球体将最终产品的湿膨胀减少大于大约5％。
53.根据权利要求52所述的配方，其中，与由等量的不含微球体的配方制造的建筑产品相比，所述微球体将最终产品的湿膨胀减少大于大约10％。
54.根据权利要求38所述的配方，其中，与由等量的不含微球体的配方制造的建筑产品相比，所述微球体增加冻-融循环下最终产品开始可视降解的循环数目。
55.根据权利要求38所述的配方，其中，与由等量的不含微球体的配方制造的建筑产品相比，所述微球体减少经过多次冻-融循环后最终产品中孔径分布的变化。
56.根据权利要求38所述的配方，其中，与由等量的不含微球体的配方制造的建筑产品相比，所述微球体影响最终产品的热收缩，从而使最终产品与不含微球体的建筑产品相比增加的热收缩小于大约50％。
57.根据权利要求38所述的配方，其中，最终产品的热收缩为大约1％-5％。
58.根据权利要求38所述的配方，所述配方还包含火山灰。
59.根据权利要求38所述的配方，所述配方还包含低容积密度硅酸钙水合物。
60.一种低密度建筑材料的形成方法，所述方法包括：
将水凝粘合剂、集料、纤维、中空陶瓷微球体和水混合造浆；
将此浆加工成绿色成形物品；和
将此绿色成形物品固化形成低密度建筑材料，所述建筑材料的密度为大约1.2g/cm3或更小。
61.根据权利要求60所述的方法，其中，所述纤维为纤维素木桨。
62.根据权利要求61所述的方法，所述方法包括将大于大约4％的纤维与水凝粘合剂、集料、中空陶瓷微球体和水混合造浆。
63.根据权利要求60所述的方法，所述方法还包括将添加剂与水凝粘合剂、集料、纤维、中空陶瓷微球体和水混合造浆。
64.根据权利要求60所述的方法，所述方法还包括将低密度添加剂与水凝粘合剂、集料、纤维、中空陶瓷微球体和水混合造浆。
65.根据权利要求64所述的方法，其中，所述低密度添加剂包含硅酸钙水合物。
66.根据权利要求60所述的方法，其中，低密度建筑材料的密度为大约0.5-1.2g/cm3。
67.根据权利要求60所述的方法，其中，所述低密度建筑材料的密度为大约0.9-1.1g/cm3。
68.根据权利要求60所述的方法，其中，通过热压处理将所述物品固化。
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
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| US18923500P | 2000-03-14 | 2000-03-14 | |
| US60/189,235 | 2000-03-14 | ||
| US09/803,456 | 2001-03-09 | ||
| US09/803,456 US6572697B2 (en) | 2000-03-14 | 2001-03-09 | Fiber cement building materials with low density additives |
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| CNA2008101871095A Division CN101575195A (zh) | 2000-03-14 | 2001-03-09 | 含低密度添加剂的纤维水泥建筑材料 |
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| JP (1) | JP5025872B2 (zh) |
| KR (1) | KR100853920B1 (zh) |
| CN (1) | CN1426382A (zh) |
| AT (1) | ATE368017T1 (zh) |
| AU (1) | AU2001250832A1 (zh) |
| BR (1) | BR0109283A (zh) |
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| MY (1) | MY126097A (zh) |
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- 2001-03-09 CN CN01808151A patent/CN1426382A/zh active Pending
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105874004A (zh) * | 2013-12-30 | 2016-08-17 | 3M创新有限公司 | 包含中空玻璃微球的聚(甲基戊烯)组合物和使用该聚(甲基戊烯)组合物的方法 |
| CN105174768A (zh) * | 2015-08-31 | 2015-12-23 | 南京林业大学 | 一种纳米纤维素纤维增强水泥基材料 |
| CN105174768B (zh) * | 2015-08-31 | 2017-06-20 | 南京林业大学 | 一种纳米纤维素纤维增强水泥基材料 |
Also Published As
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|---|---|
| JP2003527288A (ja) | 2003-09-16 |
| US20080203365A1 (en) | 2008-08-28 |
| US20030205172A1 (en) | 2003-11-06 |
| AU2001250832A1 (en) | 2001-09-24 |
| BR0109283A (pt) | 2002-12-17 |
| KR100853920B1 (ko) | 2008-08-25 |
| KR20020087077A (ko) | 2002-11-21 |
| US7727329B2 (en) | 2010-06-01 |
| JP5025872B2 (ja) | 2012-09-12 |
| DE60129538D1 (de) | 2007-09-06 |
| EP1265822A1 (en) | 2002-12-18 |
| US6572697B2 (en) | 2003-06-03 |
| US8603239B2 (en) | 2013-12-10 |
| US20120260827A1 (en) | 2012-10-18 |
| MXPA02008921A (es) | 2004-10-15 |
| ATE368017T1 (de) | 2007-08-15 |
| MY126097A (en) | 2006-09-29 |
| CA2402886A1 (en) | 2001-09-20 |
| US8182606B2 (en) | 2012-05-22 |
| DE60129538T2 (de) | 2008-04-10 |
| PL358677A1 (en) | 2004-08-09 |
| US20010047741A1 (en) | 2001-12-06 |
| US20100242802A1 (en) | 2010-09-30 |
| CA2402886C (en) | 2012-02-14 |
| US7658794B2 (en) | 2010-02-09 |
| WO2001068547A1 (en) | 2001-09-20 |
| EP1265822B1 (en) | 2007-07-25 |
| NZ521491A (en) | 2004-06-25 |
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